Flashcards
Material Resource Planning MRP
Flashcards do conjunto (18)
- 1What is MRPMRP is a computer-based inventory management PUSH system to aid production managers with the scheduling and placing of orders for items of dependent demand. Dependent demand items are components/sub-assemblies. MRP works in the opposite way to a production plan for finished goods. It begins with a schedule for a finished good and is converted into a schedule of requirements for subassemblies, parts and raw materials that are required to produce the final product.
MRP breaks down the inventory requirements into planning periods to complete production in as little time possible, while inventory levels and related carrying costs are kept as low as possible. - 2What three questions does MRP answer What is needed?
How much is needed?
When is it needed? - 3Where do MRP information inputs come from and what are they used forA bill of materials – Listing of all the raw materials, parts and subassemblies. Used to determine the quantity of each component needed to produce the number of finished products.
A master schedule – Outlines the anticipated production events.
An inventory records file – This provides an accounting of how much inventory is already available or on order, and therefore is subtracted from the material requirements.
Using the three information inputs above, the MRP system determines the net requirements for materials, parts and subassemblies for each period. It firstly determines gross material planning and then deducts out the inventory on hand and adds back in the safety stock in order to compute the net requirements. - 4Primary MRP outputs Planned order schedules – outlines the quantity and timing of future orders.
Order releases – Authorises orders to be made.
Changes to planned orders – Cancellations or revisions of the quantity or time frame. - 5Secondary MRP outputs Performance control reports – used to track problems to evaluate system performance.
Planning reports – Used to forecast future inventory requirements.
Exception Reports – These call manager’s attention to major problems such as late orders or
excessive scrap rates. - 6MRP advantages MRP reduces the stock of the finished products and the raw materials leading to reduced assets and storage requirements.
Strategic procurement leads to less/no losses in raw materials and lower production costs.
Reduction in human assembly error due to detailed bill of materials.
Improved product/component tracking leads to greater production line efficiency and makes
stock control errors easier to resolve. - 7MRP disadvantages The MRP system is difficult to implement.
Employees need educating and training - this leads to increased implementation costs and
time.
Installation of software and hardware requires a significant amount of time and money.
The proper functioning of the system is only guaranteed if the data stored in the software is
correct. Errors in the data directly affects production. Most errors are of human origin and
are easily minimized. For example, workers can use bar code scanning to help them.
The data must be updated regularly. Obsolete data makes the software ineffective.
The use of the MRP system requires an interconnection between factories of the same
company, which can be difficult and expensive to implement. - 8MRP flexibility to changesDue to MRP including internal forecast and external orders within the master schedule, the system has the ability to adapt and change the procurement and distribution of parts and components when the forecasts/orders are increased. However, order cancellations will result in an increase in stock storage and waste if these orders are not filled. Therefore, the level of flexibility can vary depending on the type of change.
- 9What is kanbanThe KANBAN method is to eliminate waste by maintaining the size of stocks at a reasonable level. In KANBAN, no separate or higher-level planning is required for material flow through production.
Kanban is a PULL system - 10Kanban types Classic KANBAN
KANBAN with Quality Signal
One-Card KANBAN
Event-Driven KANBAN - 11What is classic kanbanDemand, Supply and procedure for material replenishment are all defined within the Control Cycle as well as the number of Kanban’s that circulate between the supply source, demand source and the quantity per Kanban.
- 12What is Kanban with quality signalKanban replenishment is controlled by the value of individual quantities being withdrew by an employee, only once the Kanban signal is EMPTY is the system informed of the quantity in the system.
- 13What is one card kanbanIncludes two Kanban’s in the control cycle, which lowers the inventory level at the demand source, especially during periods when the material is not required. Replenishment is triggered when the Kanban being emptied becomes half empty, the new Kanban is then delivered when current Kanban is EMPTY.
- 14What is event driven kanbanMaterial provision isn’t based on predefined Kanban quantity or number of Kanban’s, rather it’s based on material consumption. Material is only replenished when requested and not continually provided and replenished at a supply area, this makes the replenishment system even simpler.
- 15Kanban implementation considerations Before implementing KANBAN the consumption of part and components has to be relatively constant within a specified period which is longer than the replacement lead time of a Kanban.
The supply source has to be proficient of producing a large number of small lots in a short time. - 16KANBAN flexibility to changesDue to KANBAN being a PULL system it has instance flexibility to change, as, when parts are not required, the Kanban remains in a WAIT state at the supply source until more parts are required, then the kanban is pulled into the demand source ready for manufacturing.
- 17MRP summaryIt is a PUSH system that uses software to create a bill of materials, master schedule and inventory records file to manage and control a production line. It breaks the production down into small periods of production for parts and components rather than a finished product.
- 18Kanban summaryIt is a PULL system that used cards or visual signals to control the flow of parts and components onto the production line and remains in a WAIT state if none are required. This enables a very flexible system with simple stock control.
Informações
- Descrição
- Bachelor Menelaos (Semester 2) FlashCards sobre Material Resource Planning MRP, criado por athanasia.kanell em 12-05-2016.
- Criado por
- athanasia.kanell
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